Support cradle for rolled coils and other cylindrical objects

ABSTRACT

A cradle unit for supporting metal coils, and other cylindrical objects, consists of two, parallel and separate saddles made of polyurethane having a hardness range of between 50 Shore A and 90 Shore D, which saddles are connected together via a pair of parallel steel angle-brackets that provide inherent structural integrity to the cradle unit itself, while still allowing the unit to conform to the shape or level of the underlying support structure. The single cradle unit may be as a mobile support-device, or may be bolted or otherwise attached to a surface for a specific location of the stored product. The cradle unit of the invention may, also, be attached to the bed of a transportation vehicle, such as a truck trailer or rail car, in order to provide secure, protective storage and location of the items. In this case, the nature of the resilient or soft material from which the cradle unit is made provides shock-absorption qualities for the transported coil. The cradle unit is generally concave-shaped and has a first main or central lower concave curvature of a first radius, and a middle or secondary transitional curvature that connects the first main lower curvature to an upper, tertiary concave curvature of a second radius greater than the first radius, so that coils or rolls of different diameter may be safely and firmly supported.

BACKGROUND OF THE INVENTION

The present invention is directed to a cradle unit, or supportingmember, for supporting and storing coils, such as wound rolls or coilsof long lengths of thin flat material made of steel, other metal, paper,or the like, which are processed, handled, stored and transported withthe longitudinal axis of the coil oriented in the horizontal direction.When stored in their semi-finished, in-process stage between operations,in their finished state awaiting shipment, or during actual shipment andfinal storage during actual use, these coils are placed in designatedstaging areas by supporting them on the floor, since allowing thesecoils to rest directly on the floor or other flat surface would producehighly-stressed loading at the tangential contact points. Even thoughthese coils may be made of metal, they are relatively soft or pliable,and susceptible to damage from scratching, denting or surface-markingwhen they impinge upon debris on the floor or on another hard storagesurface.

Many locations where coils are stored are on floors that are not flat,tending to misshape or deform the coil over time. Coils may also bedamaged from flattening or denting when set down during handlingoperations, or from excessive pressure or weight while sitting instorage due to single-point tangential and high surface-loading. Thissituation is exacerbated when coils are stacked during storage, which iscommon in the metals industries. Therefore, significant expense isincurred from the lost metal and rework of the damaged coils.Additionally, stacked coils, when stored on flat floors, represent asafety hazard from roll out of the bottom tier of the stack. Thissituation is hazardous to personnel, the facilities and the coils thatwould be affected by such a collapse of the stack.

There have been used a number of various techniques in an attempt toaddress the above-mentioned problems. Some of these techniques include:setting coils on rubber or fabric belting; using rubber or polyurethanepads with slight indentations to cradle the coil; using “V”-shapedblocks made of polyurethane, plastic, wood or metal; and unitized skidsof plastic, wood or metal, or other similarly constructed devices tocontain or protect the coils.

Polyurethane, rubber and plastic coil-support devices possess theability to cushion the coil during set-down. These devices are typicallymolded or formed into a single unit, and do not provide suitablestrength or structural integrity to support stacks of coils without theuse of additional, independent, and separate support structures. Woodsupports are not resilient or durable, while metal fabricated supportsdo not cushion and offer a surface that has is basically the same as abare floor. Unitized fabrications of wood, plastic or steel areexpensive to build, do not offer the durability and protection of aresilient support, and do not conform or adapt to uneven floorconditions.

An example of a prior-art support is disclosed in U.S. Pat. No.4,503,978—Smit, et al., and discloses a support for rolled coils made ofpolyethylene. The supports of this patent do not generally provideadequate structural support, and, therefore, are typically supported byU-shaped steel channels bolted to the floor, or other supportingsurfaces, and are generally not conformable to a supportunder-structure.

SUMMARY OF THE INVENTION

It is, therefore, the primary objective of the present invention toprovide a support cradle for coils, rolls, or other cylindrical objectsthat provides its own inherent structural integrity for solelysupporting a coil thereon, while also conforming to the under-structureupon which it is rests, which support cradle may be used to supportcoils or rolls of different diameter.

It is, also, the primary objective of the present invention to providesuch a support cradle that provides its own inherent structuralintegrity for supporting a coil thereon, while also conforming to theunder-structure upon which it is secured, which support may also beconnected to other like-cradles for forming a multi-unit cradle-supportfor supporting a series of coils thereon, while still maintaining itsconforming characteristics for preventing damage to the coils supportedthereon, and for safely stacking of rows of coils thereabove.

In accordance with the invention, the cradle unit for supporting metalcoils, and other cylindrical objects, consists of two parallel andseparate cradle-sections or saddles made of polyurethane having ahardness range of between 50 Shore A and 90 Shore D, whichcradle-sections are joined or connected together via a pair of parallelsteel angle-brackets that provide inherent structural integrity to thecradle unit itself, while still allowing the saddles to conform to theshape or level of the underlying support structure, whereby a pluralityof cradle units may be used for supporting coils in a tiered stack. Thesingle cradle unit may be used as a mobile support-device, or may bebolted or otherwise attached to a surface for a specific location of thestored product. The cradle unit of the invention may, also, be attachedto the bed of a transportation vehicle, such as a truck trailer or railcar, in order to provide secure, protective storage and location of theitems. In this case, the nature of the resilient or soft material fromwhich the cradle unit is made provides shock-absorption qualities forthe transported coil.

The cradle unit generally defines a concave-shaped upper surface, andhas a first main or central lower concave curvature of a first radius, apair of middle or secondary transitional curvature-sections that connectthe first main lower curvature to a pair of upper, tertiary concavecurvature-sections of a second radius greater than the first radius, sothat coils or rolls of different diameter may be safely and firmlyaccommodated.

In a modification of the invention, a multiple-unit version is providedwhere a series of cradle units of the invention are connected togetherto form one elongated integral support structural unit. Thismodification is a unitized rack that forms a row-storage arrangementwhere the stored coils or objects are stored randomly along the lengthof the rack, for securing and protecting the stored coils or objects,with the coils arranged lengthwise along the length of the rack.

In yet another modification, each cradle unit is provided withoutwardly-projecting oil-receiving pans or reservoirs for collecting oilor other liquid lubricant seeping or draining out from the ends of thecoil supported thereby. These pans provide for the containment of thefluid to prevent contamination of the surrounding environment, andprovide for safe, easy recovery and disposal of the liquid.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be more readily understood with reference to theaccompanying drawings, wherein:

FIG. 1 is an isometric view of the cradle unit for supporting a coil,roll, or other cylindrical object in accordance with the invention;

FIG. 2 is a top view thereof.

FIG. 3 is a side, elevational view thereof;

FIG. 4 is an end view thereof;

FIG. 5 is an isometric view showing a series of cradle units of FIG. 1being used to support a tiered stack of coils or rolls;

FIG. 6 is an isometric view similar to FIG. 5 showing the force vectorsacting on the coils or rolls and on the series of cradle unitssupporting the stack of coils or rolls;

FIG. 7 is an isometric view of a modification in which a series ofcradle units of FIG. 1 are provided in one unitary structure for forminga rack for supporting a series of coils, rolls, or other cylindricalobjects in a row;

FIG. 8 is an end view thereof;

FIG. 9 is a side elevational view thereof;

FIG. 10 is an isometric view showing a series of cradle racks of FIG. 7being used to support a plurality of stacked rows of coils or rolls;

FIG. 11 is an isometric view of another modification of the cradle unitof FIG. 1 with the addition of a pair of end-pans serving as reservoirsfor collecting lubricant draining from coils or rolls supported orstacked thereon;

FIG. 12 is a side elevational view thereof;

FIG. 13 is a top view thereof; and

FIG. 14 is an end view thereof.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings in greater detail, and to FIGS. 1-6 fornow, there is shown a cradle unit 10 of the invention for supporting acoil, roll, or other large cylindrical object. The cradle unit 10consists of a pair of parallel-arranged, identical end-cradle sectionsor saddles 12, 14 preferably made of polyurethane, in the hardness rangeof between 50 Shore A and 90 Shore D. The length of each end-cradlesection or saddle 12, 14 depends upon the size or sizes of the coils orrolls to be supported. In one example, each end-cradle section is thirtythree inches in length and three inches in width. Each end-cradlesection or saddle 12, 14 defines an upwardly-facing concave supportingsurface 16, 18 which consists of a first lower or main portion 16′, 18′,respectively, having a first radius R1, and second upper or tertiary endportions 16″, 18″ each having a second radius R2 that is greater thanthe radius R1. Connecting the surface-portion 16′ or 18′ with theportions 16″ or 18″ are transitional curvature-portions or regions 20,22, respectively. The values of R1 and R2 will vary depending upon thesize of coils or rolls to be supported. The value R1 corresponds to theradius of the minimal coil or roll to be supported by the cradle 10,while the value R2 corresponds to the radius of the maximal coil or rollto be supported by the cradle 10. In the example given above, the firstradius R1 is twenty inches, while the second radius R2 is thirty sixinches, with the height of each end-cradle section or saddle increasingfrom a minimum of one inch at the midpoint or center to a maximum offive inches at the extremity or end 24, 26.

With regard to the transitional regions 20, 22, it is noted that thefirst lower or main portion 16′, 18′ and the second upper or tertiaryend portions 16″, 18″ not only have different radii R1 and R2, but, ofcourse, also have different points of centers pt1 and pt2, respectively.The shape or curvature of each transition region 20, 22 is formed bygenerating a number of circles of different radii and from a varyingcenter position pt[i] between the center points pt1 and pt2 in a linearrelationship. Using the equation:pt[i]=pt1+(pt2−pt1)/(r2−r1)*abs(r1−r[i]), where pt[i] is a center pointof a transitional circle and r[i] is the radius of the transitionalcircle, connecting the tangents of these generated circles form thecurve of each transition region 20, 22.

The cradle unit 10 also includes a pair of parallel-arranged steelangle-brackets 30, 32 which provide the inherent structural integrity tothe unit. Each angle-bracket connects corresponding ends of the twoend-cradle sections 12,14, as seen in FIG. 1. Each angle-bracket 30, 32consists of a horizontal section 34 and a vertical section 36, with arespective end of a cradle unit being nestled therein. The right-anglebrackets are bonded to the ends of the end-cradle sections byconventional bonding techniques, whereby a flexible and adaptablerectilinear-shaped structure is formed. In the above-mentioned example,the length of each angle-bracket is thirty six inches, with the width ofeach of the horizontal and vertical sections being three inches, andmade of 3/16 steel. Each horizontal section 34 is provided with a pairof holes 46 for passing therethrough bolts for securing the cradle unit10 to a floor or other under-structure.

Referring to FIG. 5 and 6, it may be seen how a series of cradle units10 may be used to support a tiered vertical stack of rows of coils orrolls 40. The force vector diagram depicts coils C1 through C8 stackedon the coil cradle units 10 of the invention. The loads are calculatedas if the stack continues on to the left of the diagram. Each coil shownhas been assumed to be of a 72″ O.D. and a weight W. Because of thestacking, the downward force W splits into the two vector forces W_(L)and W_(R). For purposes of clarity, only coil C2 has been shown with theforces labeled. On the middle row, the forces acting on coil C4 are itsweight W plus W_(R) from coil C1 and W_(L) from coil C2. The resultantforce, 2·W, is drawn using vector addition. The forces acting on coil C5are its weight W plus W_(R) from coil C2. The resultant force is drawnusing vector addition. On the bottom row, the forces acting on coil C6are its weight W plus 2·W_(R) from coil C3 and 2·W_(L) from coil C4. Theresultant force, 3·W, is drawn using vector addition. The forces actingon coil C7 are its weight W plus 2·W_(R) from coil C4 and W_(L) fromcoil C5. The resultant force is drawn using vector addition. The forcesacting on coil C8 are its weight W plus 2·W_(R) from coil. The resultantforce is drawn using vector addition. On the bottom row, lines are drawnfrom the center of the coils to the edges of the ends 24, 26 of thecradle units. If the resultant force vectors remain in between theselines, the stack will be stable, assuming that the coils in the stackare frictionless and not considering inertia. In actual use, the stackcould be stable even if this limit were somewhat exceeded. Because ofthe provision of two separate upper curved sections of different radiiR1 and R2 for each cradle unit, multiple layers of coils of differentdiameter may be more safely stacked, as shown in FIGS. 5 and 6.

Referring now to FIGS. 7-10, there is a shown a modification in which aseries of cradle units 10 are provided to form a rack 50 of cradles forsupporting a plurality of individual coils thereon end-to-end to form aladder-like structure. The rack 50 consists of a plurality of cradleelements 52 similar to the end-cradle sections 12, 14 of the cradle unit10, which cradle sections 52 are interconnected together by a pairelongated steel angle-brackets 54, 56 similar to the angle-brackets 30,32 of the cradle unit 10 of FIG. 1. The spacing between the cradleelements 52 is generally less than the spacing between the end-cradlesections or saddles 12, 14 of the cradle unit 10. Whereas the spacingbetween the cradle sections 12, 14 in one example cited above is thirtyinches, the spacing between adjacent cradle elements 52 is 15¼ inches,so that, not only variously-sized rolls or coils of different diametersmay be supported and stored on the rack 50, but also coils or rolls ofdifferent lengths may be supported thereby. In addition, owing to theseries arrangement of cradle sections 52, the placing of a coil or rollon the rack 50 may be achieved at any portion along the length thereofthereby allowing facility of placement and storage. A plurality of racks50 may be employed in parallel formation, as shown in FIG. 10, in orderto allow for support and storage of multiple, stacked rows of coils orrolls 40. The spacing between racks 50 is dependent upon the size of thecoils or rolls 40 to be supported. Each individual rack 50 is bolted tothe floor or under-structure by bolts passing through theangle-brackets, in the same manner described above with reference to thecradle unit 10. In addition, oil pans similar to oil pans describedhereinbelow with reference to FIGS. 11-14, may also be used forcollecting oil, or other fluid. It is noted that the individual rolls orcoils are supported end-to-end, with their longitudinal axes beingparallel to the length of the rack, whereby the rack 50 supports them inthe manner that has hithertofore only been done using a coil pad. Thus,the rack 50 serves the dual function of acting as cradle supports and asa coil pad.

Referring now to FIGS. 11-14, there is shown another modification 60 ofthe cradle unit 10 in which a pair of oil-collecting pans or reservoirs62, 64 are provided at the ends of the cradle unit in order to collectoil or other lubricant or fluid seeping or draining out from the ends ofthe coil supported thereby. These pans provide for the containment ofthe fluid to prevent contamination of the surrounding environment, andprovide for safe, easy recovery and disposal of the liquid. Eachoil-collection pan 62, 64 is preferably formed integrally with therespective cradle section 12, 14, and typically has a width of twelveinches and a length of two feet. Each pan 62, 64 is provided with anupstanding lip or rim 62′, 64′ for containing the oil. The rest of thecradle unit 60 is substantially identical to the cradle unit 10.

The cradle of the invention adapts readily and inherently to the contourof the underlying support structure or floor, with the spacing betweenthe angle-brackets and between the saddles providing a self-adaptingunitary structure, so that uneven or contoured floors will not adverselyaffect the support provided by the cradle of the invention. Moreover,the inherent resiliency of the material used in the saddles offershock-absorption characteristics.

While the preferred material for the saddles has been indicated as beingpolyurethane, other, comparable or equivalent material may be usedinstead, or composites thereof, as long as these other materials arewithin the same hardness range of between 50 Shore A and 90 Shore D.Some of these other materials are, for example: nylon; nyrim;polyethylene of all molecular weights (ultra high, high density, mediumdensity, low density, copolymers, homopolymers); rubber such as SBR,EPDM, nitrile, Neoprene (polychloroprene), natural, Hypalon(chlorosulfonated polyethylene rubber), butyl; granulated and rebondedrubber; and recycled plastics; recycled plastic/wood flour or othersimilarly formulated blends; polypropylene; vinyl (PVC).

While specific dimensions have been given hereinabove, it is to beunderstood that these have been given only by way of example. The actualdimensions may vary depending upon the lengths and diameters of thecoils or rolls intended to be supported.

While the transition regions 20, 22 have been described as having shapeor contour described hereinabove, it is to be understood that othermethods for producing the shape or contour thereof may employed, as wellother different shapes and curvature.

While a specific embodiment of the invention has been shown anddescribed, it is to be understood that numerous changes andmodifications may be made therein without departing from the scope andspirit of the invention as set forth in the appended claims.

1. A support cradle for supporting coils, rolls, and other cylindricalobjects, comprising: a pair of parallel saddle elements made of amaterial in the hardness range of between 50 Shore A and 90 Shore D;each said saddle element comprising a concave upper surface upon whichrests a portion of a coil or roll; said concave upper surface defining acentral, lower curved section of a radius R1, and a pair of terminalupper curved sections each of a radius R2 greater than R1, and pair oftransitional sections, each said transitional section transitioning fromsaid central, lower curved section to a respective one of said pair ofterminal upper curved sections, said radius R1 corresponding to theminimum radius of a coil or roll to be supported by said pair ofsaddles, and said radius R2 corresponding to the maximum radius of acoil or roll to be supported by said pair of saddles; and a pair ofparallel connecting elements, each said connecting element connectingcorresponding ends of the said pair of saddle elements in order to forma rectilinear-shaped structure.
 2. The support cradle for supportingcoils, rolls, and other cylindrical objects according to claim 1,wherein said material from which said pair of parallel saddle elementsis made is polyurethane.
 3. The support cradle for supporting coils,rolls, and other cylindrical objects according to claim 1, wherein eachof said pair of parallel connecting elements comprises an angle-bracketconsisting of a vertical section and a horizontal section, therespective said corresponding ends of said pair of parallel saddleelements being nestled therein and affixed thereto.
 4. The supportcradle for supporting coils, rolls, and other cylindrical objectsaccording to claim 3, wherein said material from which said pair ofparallel saddle elements is made is polyurethane.
 5. The support cradlefor supporting coils, rolls, and other cylindrical objects according toclaim 3, wherein each said horizontal section comprises mounting holesfor receiving bolts for securing the cradle to an underlying structure.6. The support cradle for supporting coils, rolls, and other cylindricalobjects according to claim 1, further comprising fluid-reservoir meansfor collecting fluid flowing out from the object supported thereon. 7.The support cradle for supporting coils, rolls, and other cylindricalobjects according to claim 6, wherein said fluid-reservoir means forcollecting fluid comprises a pair of fluid-collecting means, one saidfluid-collecting means extending away from one of pair of said saddleelements and the other said fluid-collecting means extending away fromthe other of said pair of saddle elements.
 8. The support cradle forsupporting coils, rolls, and other cylindrical objects according toclaim 1, comprising a series of said support cradles connected totogether to form a rack of row-storage arrangement of support cradles;said rack comprising said pair of parallel connecting elements whichconnect corresponding ends of respective pairs of said saddle elementsof all of said series of support cradles.
 9. A method of using supportcradles for supporting coils, rolls, and other cylindrical objects,where each support cradle comprises a pair of parallel saddle elements,with each said saddle element comprising a concave upper surfacedefining a central, lower curved section of a radius R1, and a pair ofterminal upper curved sections each of a radius R2 greater than R1, andpair of transitional sections transitioning from said central, lowercurved section to said pair of terminal upper curved sections, and apair of parallel connecting elements each connecting corresponding endsof said pair of saddle elements in order to form a rectilinear-shapedstructure, said method comprising: (a) supporting on said concave uppersurface a cylindrical object of a radius approximately equal to saidradius R1; (b) supporting on said concave upper surface a cylindricalobject of a radius approximately equal to said radius R2. (c) said step(a) comprising supporting the cylindrical object via contact againstsaid central, lower curved section of radius R1; (d) said step (b)comprising supporting the cylindrical object via contact against saidterminal upper curved sections of radius R2.
 10. The method of usingsupport cradles for supporting coils, rolls, and other cylindricalobjects according to claim 9, wherein said step (a) comprises supportingthe cylindrical object of a radius approximately equal to radius R1 onsaid on said concave upper surface of a first cradle support; said step(b) comprising supporting the cylindrical object of a radiusapproximately equal to radius R2 on said on said concave upper surfaceof a second cradle support.
 11. The method of using support cradles forsupporting coils, rolls, and other cylindrical objects according toclaim 9, wherein said step (a) comprises supporting the cylindricalobject of a radius approximately equal to radius R1 on said concaveupper surface of one cradle support; removing the cylindrical object ofradius approximately equal to radius R1 from said concave upper surfaceof the one cradle support; and said step (b) comprising supporting thecylindrical object of a radius approximately equal to radius R2 on saidconcave upper surface of the same cradle support as said step (a). 12.The method of using support cradles for supporting coils, rolls, andother cylindrical objects according to claim 10, further comprisingrepeating said steps (a) and (b) a multitude of times for forming abottom layer of a series of supported cylindrical objects, and,thereafter, stacking at least two additional layers of supportedcylindrical objects thereon to form a layered stack of storedcylindrical objects; said step of stacking comprising supporting eachcylindrical object of said step of stacking on and between two adjacentcylindrical objects contained in the layer therebelow.
 13. A rack ofsupport cradles for supporting coils, rolls, and other cylindricalobjects, comprising: a series of parallel-arranged saddle elements, eachsaid saddle element being made of a material in the hardness range ofbetween 50 Shore A and 90 Shore D; each said saddle element comprising aconcave upper surface upon which rests a portion of a coil or roll; saidconcave upper surface defining a central, lower curved section of aradius R1, and a pair of terminal upper curved sections each of a radiusR2 greater than R1, and pair of transitional sections, each saidtransitional section transitioning from said central, lower curvedsection to a respective one of said pair of terminal upper curvedsections, said radius R1 corresponding to the minimum radius of a coilor roll to be supported by said pair of saddles, and said radius R2corresponding to the maximum radius of a coil or roll to be supported bya said saddle; and a pair of parallel connecting elements extendingtransversely with respect to said series of saddles elements, each saidconnecting element connecting corresponding ends of said series ofsaddle elements in order to form a ladder-like structure; saidrectilinear structure defining a length parallel in the direction of thelength of said pair of connecting elements.
 14. The rack of supportcradles for supporting coils, rolls, and other cylindrical objectsaccording to claim 13, wherein each of said pair of parallel connectingelements comprises an angle-bracket consisting of a vertical section anda horizontal section, the respective said corresponding ends of saidseries of parallel saddle elements being nestled therein and affixedthereto.
 15. The rack of support cradles for supporting coils, rolls,and other cylindrical objects according to claim 13, wherein saidmaterial from which each said saddle element is made is polyurethane.16. The rack of support cradles for supporting coils, rolls, and othercylindrical objects according to claim 13, in combination with a seriesof cylindrical objects supported thereby; each said cylindrical objectdefining a longitudinal axis; said series of cylindrical objects beingarranged on said series of saddle elements along the lengths thereof sothat the longitudinal axes thereof are parallel to said length of saidladder-like structure, whereby the series of cylindrical objects arearranged end-to-end with each said cylindrical object being supported byat least two of said series of saddle elements.